WORKSHOP MANUAL MD21A-MD32A AQD21A-AQD32A marine diesel engines
TROUGERON
VTOT TO
DENTO
INTRODUCTION
This workshop manual contains descriptions of repair work on the MD21A, AQD21A, MD32A and AQD32A marine
Since there are differences between the various models, as far as optional equipment is concerned, it is important that you state the engine type and serial number when ordering snare parts or in correspondence.
The instructions in this manual describe the most suitable repair methods assuming the use of certain special tools, listed under the heading "Special Tools".
We reserve the right to make alterations in design and for this reason the contents of this manual are not binding.
AB VOLVO PENTA
Technical Information Dept.
NEW MEASUREMENTS UNITS
For a long time technicians have endeavoured to find an internationally standardized system of measurements. Such a system was eventually established in 1960 and was given the name SI (Systéme International d'Unites). To a great extent, it is based on previous systems, expect that the units are uniform, i.e., no conversions are needed.
The Europeen industry is now starting to use this SIsystem.
The new SI-units are included in this book. Units used earlier are given within brackets.
The units are:
Power is given in kW (kilowatt) Previous unit h.p. (horsepower)
Torque is given in Nm (Newtonmetre) Previous unit kpm (kilopondmetre)
Engine revolutions are given in r/s (revolutions per second) previous unit r.p.m. (revolutions per minute)
Volume is given in dm3 (cubic decimetre) Previous unit 1 (litre)
CONTENTS
| Presentation | .2–5 |
|---|---|
| Removing | |
| Electrical system, exhaust manifold | 6 |
| Sea-water pump, fuel injection pump | 7 |
| Heat exchanger | .8–9 |
| leat exchanger | • | • • | • | • | • | • | • | • | • | • | .8–9 |
|---|---|---|---|---|---|---|---|---|---|---|---|
| resh-water pump | • | 9 | |||||||||
| vlinder head, timing gears | • | • | • | • | 10 | ||||||
| ubricating oil pump, camshaft | • | 11 | |||||||||
| connection rods crankshaft, liners | 12 |
Fitting
| Crankshaft |
|---|
| Cylinder liners, pistons |
| Piston rings |
| Lubricating oil pump, crankshaft drive |
| Cylinder head, valves |
| Sea-water pump |
| Circulation pump, feed pump |
| Adjusting fuel injection pump |
| Injections, glow plugs |
| Oil cooler |
| Fuel filter, exhaust elbow |
| Wiring diagram: Engine |
| Wiring diagram: Instrument panels |
| Special tools |
| Technical Data |
Presentation
Port side MD 21 A with Boro-Warner reverse gear
Starboard side, MD 21 with RB reverse gear
- Water-senaration fuel filter
- Glow plug
- Engine number 2.
- Δ. Injector
- Lubricating oil filter
- Sender temperature gauge
- Sender oil pressure gauge l ift evelet
- 8
- a. Oil cooler, reverse gear
- 9. 10. Drain plug for cooling water
- 11. Connection, sea water
- 12. Reverse gear, Borg-Warner
- Flywheel housing
- 14 Drain plug, fresh water (located on block)
- Starter motor
- Oil cooler, engine 16.
- Oil diostick
- 17. Return to fuel tank
- 19. Drain point for sea water
- 20 Fusing
- 21 Fuel injection pump
- 22. Sender - rev counter
- Water-cooled exhaust elbow
- 20. Separate water outlet
- 25. Oil scavenging oumo
- 26. Intake silencer
- 27. Water-cooled exhaust manifold combined with intake manifold
- Oil filler cap 28
- Charging regulator
- 31 Filler cap fresh water
- 32 Connection to expansion tank
- 33. Sea-water pump
- 24 Drain plug, sea water
- 35. Alternator or dynamo
- 20. Feed pump with hand primer
- 37 Drain cock, sea water
- 38 Drain plug, sea water
-
39. Connection, sea water
- Reverse gear type RB
- 41. Alternator
- 42. Type designation, reverse gear
- 43 Zinc plug (inside cover)
- 44. Fuel line to feed pump
- 45 Glow plug resistor
- 46. Glow plug relay
MD 32 A 6-cvl. – 106 h.p.
Starboard side, MD 32 A with Borg-Warner reverse gear See page for explanation of numbers
3
See page 5 for explanation of numbers
Oil filler cap Cover for gear mechanism Oil diostick Serial production number Rubber block Steering arm Water cooled exhaust albow Ail covensing pump Intake silencer Water-cooled exhaust manifold with intake manifold Oil filler coo Charging regulator Connection board Lift eyelet Heat exchanger Averoressure value Sea-water pump Alternator Feed pump with hand primer Lubricator (located on flywheel housing) Surplus water hose Cooling water Plug for gear cable grommet Outlet, surplus water Cooling water intake Outboard drive model 270D Corrosion protection Exhaust outlet with trimming lab Fuel filter with water separator Filler can cooling water Glow plug Serial production number Injector Oil filter Oil pressure sender Temperature gauge sender Elec mechanical drive lift Flexible casing Mounting collar Plug for gear cable grommet Flywheel housing Drain cocks (on block, exh. man., Starter motor Oil cooler Oil dipstick Type data plate Connector for fuel lines Front support member Fuel injection pump Sender for rev counter
Plug, heat exchanger
AQD 21 A 4-cyl. – 75 h.p.
AQD 32 A 6-cyl. – 106 h.p.
Port side, engine unit AQD 32 A
Repair Instructions
in the cooling water and the oil from the engine: then
emoving
ecuical system, exhaust manifold
Remove the following parts: the alternator ground by the cable for the engine speed sender, the charging gulator and the nuts for the attaching plate, the drive if for the alternator and the alternator, the clamps for the ble harness, the cables from the starter motor, the cable the water temp. sender in the cylinder head and the ble for the oil pressure in the oil cooler.
Remove the intake silencer and the hose from the oil
Hemove the bolts that are locked with lock wire on the thatst manifold (exhaust elbow — heat exchanger). telease the other bolts and nuts on the exhaust manifold ind pull off the manifold from the studs.
4. Remove the oil pipe for the rocker mechanism (located behind the exhaust pipe). Scrap the copper washers.
5. Remove the feed pump with fuel pipe after slackening the pipe clamps.
6. Remove the two bolts on the engine speed sender and lift up the sender.
seawater pump, fuel injection pump
7 Remove the sea-water pump. The bracket for the heat exchanger is released at the same time (MD21). Pull the pump straight out after the hose clamp and hose have been removed from the pump.
11. Remove and scrap the oil filter. Then remove the oil cooler
12. Remove the fuel injection pump and delivery pipes, also the bracket for the control. Protect the pipe ends with protective caps.
Remove the water pipe between the oil cooler and water
Remove the starter motor and the drain cock on the side.
10 Disconnect the delivery pipes from the injectors. Remove the protective caps from the spark plugs and take off the elctric cable plate.
13. Remove the leak-off oil pipe from the injectors. NOTE. Scrap the copper washers. Screw back the banjo screws as a protection.
Aremove the forks for the injectors. Then pull out the network Mark them to ensure that they are replaced in the sine order when installing. Fit protective caps.
17. Undo the stainless steel nuts holding the thermostat. Remove the thermostats in order to check the opening temperature.
15 Remove the glow plugs.
hemove the screws for the heat exchanger cover and coll the cover.
18. Release the other screws and hose clamps on the heat exchanger. Remove the hoses. NOTE. The small hose under the heat exchanger on the MD32 cannot be removed until the heat exchanger has been pulled straight up.
19. Remove the plate with the lift eyelet and scrap the gaskets. On late prod. type engines, the lift eyelet has been moved to the cast-iron part of the heat exchanger. The plate with gaskets between the exhaust manifold and gear exchanger is of the same design as previously, apart from the lift eyelet with the threaded attachment. The picture below shows the earlier type. The new type of plate terminates at the arrow.
0. Remove the end cover on the part side of the heat
21 Remove the cast iron part or end cover on the starboard side: Take out the tube insert. Remove the O-rings. Wash and blow clean all the heat exchanger parts. Check thoroughly to make sure that the tube insert channels are free from impurites. Remove the old zinc elektrodes and fit new ones.
22. Fit new O-rings on the tube insert the tube insert in the heat exchanger and screw on the ends.
Fresh-water pump
23. Remove the water pump from the cylinder head. The pulley can be taken off after the center nut has been removed.
noving the cylinder head and timing gears
Remove the rocker casing, inspection covers, valve ket, push rods and valve lifters. Unscrew all the nder head bolts. NOTE. The bolts have three different the Lift off the cylinder head and gasket.
27. Remove the vibration damper from the flywheel. Remove the timing gear casing. Remove the circlip for the idler gear. Pull the idler gear straight up.
25. Remove the pipe for the oil scavenging pump. Look out for any oil remaining in the engine. Place a vessel under the pipe connection.
26. Remove the large nut on the front end of the crankshaft. Place a stop in the flywheel teeth. Pull off the pulley. NOTE. Take care of the key.
28. Knock up the tabs on the lock washer on the flywheel. Remove the bolts.
NOTE. Scrap the lock washer and bolts. Lift off the flywheel.
e Removing the lubricating oil pump, camshaft
29. Remove the inner flywheel casing. This casing is located by means of two guide tubes. Behind the casing there is an O-ring which must be replaced.
32. Unscrew the two bolts behind the gear wheel on the camshaft. Pull out the shaft together with the gear wheel.
30. Remove the thrust washer for the oil pump. Take care of any shims. Invert the engine. NOTE. Pretect the cylinder head face. Remove the sump. Scrap the gasket. Clean the contact surface for the gasket.
31. Remove the oil pump by undoing the cap nut on the port side of the engine. Then screw out the internal hex bolt. Pull up the pump.
33. Unscrew the bolts for the inner timing gear casing. NOTE. The slotted screw is locked with punch pops which must be knocked up. Then pull out the casing from its guide pins.
wing connecting rods, crankshaft, liners
Release the nuts for the connecting rods. Mark the necting rods with figures or points to ensure that they refitted in the same place after reconditioning. Care-
36. Turn the engine block to the proper position and screw tight the liners with the special bolts. Use special tool, part No. 884382. Measure the liner height above the top surface of the block. The height should be between 0.025-0.09 mm (0.0010-0.0035").
7. Release the nuts for the main bearing caps. Remove the ps. Lift up the shaft.
Take sure that the caps are re-fitted in the same place
37. If the liners are too low or if there are faults and abnormal wear, remove the liners with tool 884231 and scrap them. Clean round the engine block and other parts which will be used again.
Fitting
Crankshaft
38. Invert the engine. NOTE. Protect the cylinder head face. Shape and fit the graphite packing with your hands. Then tap the packing down into its slot with tool 884235. Cut off the projecting part. Then carefully cut the gasket flush with the contact surface.
Wrong
Right
Fitting the crankshaft
40. Fit an axial bearing on each side of the intermediate main bearing with the oil grooves facing outwards.
41. Oil the bearing halves. Fit the caps with the bearing halves. Check the marking on the caps to ensure that they are re-fitted in the same place as before removal. Turn the marking to face the injection side. Fit the side seals on the rear cap. The projecting part of the seal is cut off 0.5 mm (0.02") above the contact surface. Use a feeler gauge.
39. Fit the bearing shells with oil grooves. NOTE. The hole in the bearing shell must coincide with the hole in the bearing seat. Oil the bearings. Fit the crankshaft.
Tighten the bolts in stages with a torque wrench to 100 n (10 kpm = 72 lb.ft.). Oil the bolts before tightening m. Turn over the crankshaft. Check to make sure the inkshaft rotates easily without jamming.
linder liners
3. If necessary, fit new cylinder liners without seals. Lock the liners with lock bolts 884382.
Check that the edge of the liner is D-025-0.09 mm 0.0010-0.0035") above the cylinder block. Use a dial indicator. Pull out the liners and fit new rubber seals. Make
sure the seals are fitted properly. Turn the marking on the liners (1 or 2 grooves) to face the injection side.
Cylinder liner kits
Where a piston or cylinder liner must be replaced, this should be done as complete unit (this applies to the C and X marked kits), since the piston, cylinder liner and seal are matched together.
NOTE. A late prod. type cylinder head gasket must absolutely be fitted when replacing a cylinder liner. The gasket is included in the cylinder liner kit for a whole engine, but not in the cylinder liner kit per cylindet, where the gasket must be ordered separately. NOTE. The cylinder head gasket must be replaced even when only changing one cylinder liner kit.
Pistons
44. When replacing a piston, the piston bolt can easily be removed if the piston is first heated to about 80°C (176°F). Scrap the bolts and nuts on the connecting rods. Knock out the old bolts. Tap in the new ones with a hammer and drift. Fix the connecting rod in a vice with protective jaws.
45. Fitting new pistons. Insert a circlip (4). Heat the piston to about 80°C (176° F). Fit the connecting rod so that its figure marking (1) faces the piston's "clover leaf" (2). Press in the piston bolt (3) and fit the other circlip. Then fit the bearing halves on the connecting rod and cap. Check that the bearing halves are fitted properly. Oil the piston and bearing surfaces.
14
Piston rings
46. Fit the piston rings wiht the help of piston ring pliers. Start with the oil scraper ring in the bottom groove. Thereafter fit the two similar rings which are marked "TOP" on one side. This marking must face up when fitting. Fit the top ring, which is chromium-plated. Turn the rings so that their gaps are displaced in relation to each other. NOTE Monopol piston rings are neither marked with
letters nor figures. On the other hand, these rings have a bevel on the inner diameter which must face up when fitting the rings.
47. Place the tool 884234 on the block (see picture). Oil pistons and tool well. The clover leaf marking on the piston crown should face towards the injection side during the fitting. Squeeze the rings in the tools and at the same time carefully tap the piston downwards with a wooden handle or similar. Fit accordning to the marks made on removal. Start with the pistons that are at top dead center. Then place the engine on its side and fit the bearing halves on those pistons that are installed. Therafter turn the crankshaft until the next piston is at top dead center. Fit the piston and bearing half. Tighten the nuts with a torque wrench. Tightening torque = 60 Nm (6 kpm = 43 lb.ft).
48. With the crankshaft, connecting rods and pistons fitted and the bearing cap bolts and connecting rod nuts tightened according to the prescribed torques, check to make sure that the torque for turning over the crankshaft does not exceed 60 Nm (6 kpm = 43 lb.ft.).
49. Check the camshaft cam and bearing positions. Lubricate and fit the camshaft. When replacing only the gear wheel, unscrew the two bolts behind the gear wheel and then draw the camshaft forwards so that one of the claw pullers can be placed behind the gear. When fitting the new gear wheel, it should first be heated to 80°C (176° F). Tighten up the two bolts holding the camshaft.
50. Fit the inner timing gear casing. Use new gaskets. Grease the contact surface. At the same time tighten securely the attachment for the alternator bolts. Lock the slotted screw with punch pops. The location of the casing is determined by the two guide pins.
ricating oil pump, crankshaft drive
The lubricating oil pump is of the gear type and should e an axial clearance (gear wheel) of between 0.02-0.06 (0.0008-0.0024") and backlash of between 0.15-0.25 (0.006-0.010") Check the pump housing for wear, ing and leakage. Worn or damaged parts are to be aced. Also if the housing is so badly worn, the entire up should be replaced.
n the pump in its proper direction and fit it to the nder block. Fit the stop bolt and tighten up the mut Do not forget the copper washer. Tighten the
pressure plug lightly without shims. Measure the distance between the pressure plug and the block with the help of a feeler gauge. (See Fig.)
52. Fit shims under the pressure plug with a thickness corresponding to the measured clearance plus 0.05-0.10 mm (0.002-0.004") in order to obtain the correct clearance between pump and pressure plug. Shims are available in the following thicknesses: 0.1-0.2-0.5 and 1.0 mm (0.004-0.008-0.020 and 0.040"). Place the suction pipe at
the correct level so that the washer is exposed to light pressure from the spring. Fit the pipe so that the edge of the washer is 119 mm (4.7") from the contact surface of the oil sump on the MD21 and 155 mm (6.1") on the
MD32. Check to make sure that the end of the suction line reaches into the strainer at least 10 mm (0.4").
53. Thoroughly clean the strainer in the sump. Release the screws securing the strainer. Wash with paraffin or similar. Screw tight the strainer when the sump has been cleaned.
54. Apply Permatex or corresponding to the edge of the block and the sump. Fit the new gasket on the block and fit on the sump. Tighten the bolts properly. NOTE. The holes at the front edge of the engine are through-holes so that bolts, washers and nuts must be used.
55. Fit the key and gear drive on the crankshaft.
56 Fit the idler gear. Check that the line-up marking coincides with the marking on each gear and tooth opening. See Fig. below. Feel to see whether the gear wheels are stiff. There should be a certain backlash. Fit 1 mm (0.4") spacer vashers on the idler gear shaft and fit the circlip. There should be an axial clearance of between 0.10-0.15 mm (0.004-0.006"). If the clearance is excessive, carefully knock in the shaft. Place a feeler gauge leaf between circlip and spacer washer.
58. Check the front vibration damper (pulley) for any damage to the sealing surface. Engines with an engine number figher that 424673 (MD32) have a new type of vibration damper marked with a V. On changing the vibration damper, the new type should be fitted. Place the key in the slot on the crankshaft and fit the pulley carefully so that the sealing ring on the timing gear casing is not damaged. Apply Loctite to the threads and screw on the nut. Tighten up with a torque wrench (for the MD32) to a torque of 210 Nm (21 kpm = 152 lb.ft.). On the MD21 a lock washer and nut are used. The tightening to nut are used to the MD21 should be 170 Nm (17 kpm = 123 lb.ft.).
Cylinder head
59. Remove the valve springs with the help of a valve remover and take off all valve spring retaining locks. Remove the inner and outer valve springs. Place them on a rack in their proper order to ensure correct re-fitting.
57. Remove the sealing ring (1) on the timing gear casing and fit a new ring. Turn the sealing lip to face inwards towards the casing. Apply grease to the inner timing gear casing. Tighten up the two bolts in the casing before fitting on the gasket. Grease the other side of the gasket. Use a new gasket. Fit the outer timing gear casing.
60. Remove the valves, NOTE. Place the valves on a rack in the order of removal. Burnt valves are to be scrapped if wear is excessive and damaged seats are to be milled or replaced if necessary (see "Technical Data"). Seat and valve should be ground together to ensure that the contact surface are absolutely tight and do not leak. (See Fig. 60.)
| 61. Guide | Mark. | Outer diam. | , | Ream to | |
|---|---|---|---|---|---|
| 1st oversize | WHITE | 14.13 (0.556) |
0
0.011 {0.0004} |
14 (0.55) |
+0.025 (0.0010)
+0 |
| 2nd oversize | YELLOW | 14.29 (0.563) |
0
0.011 (0.0004) |
14.2 (0.559) |
+0.025 (0.0010)
+0 |
| 3rd oversize | BLUE | 14.59 (0.063) | 0 | 14.5 (0.570) |
+0.025 (0.0010)
+0 |
in.)
Valves
Meas. in mm (in.)
| 63. | Intake valve | Exhaust valve |
|---|---|---|
| Disc diam.: a |
38.5 (1.52) D21
40.5 (1.60) D32 |
31.5 (1.24) D21
33.5 (1.32) D32 |
| Seat angle: ∝ | 45° | 450 |
| Spindle diam.: b |
8.52 (0.335)
-0.025
(0.0010)
-0.047 (0.0019) |
8.5 (0.334)
-0.025
(0.0010)
-0.047 (0.0010) |
| Length : c | 116.25 (4.58) | 116 25 (4 58) |
ŕ
The value seat bevel angle should be 45°. The bevel should be between 2.2 and 2.5 mm (0.09 and 0.10") in width
Valve springs
Meas. in mm (in.)
| 62. c |
Outer spring
RH coil |
Inner spring
L-H coil |
|---|---|---|
| MD21 length | 24±0.5 (0.94 ± 0.02) | 20 ± 0.5 (0.80 ± 0.02) |
| with load | 37 kp (81 lb.) | 15.5 kp (34 lb.) |
| MD32 length | 26 ± 0.5 (1.02 ± 0.02) | 22 ± 0.5 (0.87 ± 0.02) |
| with load | 46 kp (101 lb.) | 45.8 kp (100 lb.) |
Replace damaged springs.
65. The measurement between the valve disc and the face of the cylinder head should be: 1 +0.15 mm (0.04 +0.006").
66. The bevel angle of the valve disc should be 45° and the measurement L should not exceed 3.3 mm (0,13").
Cylinder head
67. The cylinder head is made of light-alloy. The original height measured from contact surface of the head to the face for the cylinder head bolts = 90± 0.015 mm (3.54 ± 0.0006").
NOTE. After the surface has been ground smooth, the height measurement A must not be less that 89.35 mm
68a. Checking the cylinder head face
With any such repair work where the state of the cylinder head surface is involved, check the face as follows:
After completely disassembling the cylinder head, clean it thoroughly. Measure with the help of a straight edge (check the edge on a flat surface). Place the straight edge on the cylinder head face as indicated by the arrows. Then measure with a feeler gauge the space between the straight edge and the cylinder gead face at the measuring points.
A space of maximum 0.00–0.20 mm (0.00–0.008") measured diagonally (crosswise on the face) and 0.00–0.10 mm (0.00–0.004") measured laterally (transversely across the face) is approved. Grind the face if there is deviation of up to max, 0.50 mm (0.02") from these measurements. If
the measured exceeds 0.50 mm (0.02"), the cylinder head must be replaced with a new one.
68b. Procedure before face grinding
Before carrying any face grinding, remove the prechambers because they have harder metal than the cylinder head. The prechambers can be knocked out with the help of a 6 mm (1/4") thic:. metal drift, which is inserted through the recesses for the injectors. As a rule, the guide pin "A" remains in position during removal. Should any pin
accompany the chamber when being removed, knock the pin down to 0.7 mm (0.028") below the cylinder head face.
68c. Procedure in connection with face grinding In connection with face grinding, the prechambers should be lathed lower the same amount as the cylinder is ground.
elathing should be done on the prechamber's flat surface
d. Fitting after face grinding
asure the depth to both the "X" and "Y" faces of the ity for the prechambers (see Fig. 68 b), also the responding heights x and y of the prechambers (see Fig. c). There should be a space of 0.1 to 0.5 mm (0.004 to 2") between the "Y" faces when a prechamber is at its from position, see Fig 68 d.
pate the prechambers in position for the guide pins and efully tap the prechambers in until they bottom. Note if the guide pins should be knocked down to 0.7 mm 028") below the cylinder head face, see "A", Fig.2. If a
L0 - 0.03 mm
echamber is stiff when fitting, shrink it by means of oling. The face of the prechambers may not project titide the cylinder head face by move that max. 0.03 mm 0012"), see Fig 68 d.
Thoroughly clean the cylinder head, valve guides and live seats. Use a small bruch. See Fig. below. Check that the rel on the seats is perfectly finished by coating marking
colour on the valve disc bevel and then by rotating it against its seat under light pressure. If marking colour spreads unevenly over the bevel surface of the whole of the seat (leaking valve), grind the valve again and make a new check until a satisfactory result is reached.
0. Oil the valve stems before fitting them in their espective guides. See Fig. NOTE: Make sure that the valves and valve springs are fitted in their original positions. Place
the cylinder head on its edge and fit the valve springs and the valve spring retaining locks.
71. Fit the dowels, 884384 (without stem) diagonally on the well-cleaned surface of the top side of the block. Fit on a new gasket. NOTE. If any liner has been replaced, a late prod. type gasket must be fitted.
72. Clean the cylinder head surface and fit it on. Screw in the cylinder head bolts by hand. NOTE. The bolts have three different lengths.
Remove the two guide bolts with the help of the stem which has a left-hand thread. Then screw in the remaining two bolts.
Tighten the bolts in the sequence shown in the Fig. ow that is, in two stages. First stage; to a torque of 35 i (3.5 kpm = 25 lb.ft.): second stage; to a torque of 70 (kpm = 50 lb.ft.). See Fig. below. Use a torque wrench if special tool 884230.
he cylinder head bolts of a re-fitted cylinder head should final-tightened after the engine has run for 20 hours. The gine should be cold when this is carried out. (Should have een stopped for at least 6 hours.) During launching each ason, the cylinder head bolts should be check-tightened in he following way:
ark the bolt head in relation to the cylinder head. Slacken bolts 1/4 turn. Re-tighten all bolts with a torque rench to a torque of 70 Nm (7 kpm = 50 lb.ft.). The arking on the bolt head should be opposite or past the arking on the cylinder head. With the same torque,
tightening must be continued until the initial position is reached since any impurities in the bolt threads are probably preventing correct tightening.
74. Clean and oil the valve lifters and the seats for the valve lifters. Place the valve lifters in their original position and insert the push rods.
75. Fit the bracket. NOTE. The oil channel must be installed correctly from the beginning. Check that the gasket A is in good condition. On the AQD (MD)21 there should be a clearance of 0.1 mm (0.04") between the outer rocker arms and the support brackets.
76. The engine must be cold when adjusting the valves, that is, it should have been stopped for at least 6 hours. The valves must not be adjusted when the engine is running.
77. When an engine has been reconditioned, the cylinder head bolts should be final-tightened after the engine has run for 1 hour
The cylinder head bolts should be tightened again after a further 20 hours of operation or if the engine has been stopped longer than 3 months. IMOPORTANT! Final-tightening should be done when the engine is cold, which means at least 6 hours after it has stopped. After final-tightening the cylinder head bolts, adjust the valves. Turn over the engine so that the respective exhaust valve according to the table below fully opens. Then adjust the valves according to the table.
| Preadjus | tment of valves | Open valve fully |
|---|---|---|
|
13 and E4
14 and E2 |
E1
E3 |
|
| MD21 | 12 and E1 |
E4
E2 |
Valve clearance:
Before first start 1 hours's operation 20hours' op. or more Inlet valves: 0.25 mm (0.010'') 0.25 mm (0.010'') 0.15 mm (0.006'') Exhaust valves: 0.35 mm (0.014'') 0.35 mm (0.014'') 0.25 mm (0.010'')
| Preadjus | tment of valves | Open valve fully |
|---|---|---|
| MD32 |
15 and E3
13 and E6 16 and E2 12 and E4 14 and E1 11 and E5 |
E1
E5 E3 E6 E2 E4 |
Valve clearance:
Before first start 1 hours's operation 20 hours' op. or more Inlet valves: 0.25 mm (0.010'') 0.25 mm (0.010'') 0.15 mm (0.006'') Exhaust valves: 0.35 mm (0.014'') 0.35 mm (0.014'') 0.25 mm (0.010'')
NOTE! Do not take out full engine output before finaltightening at 20 hours' operating time.
the rocker casing groove with Permatex. Place the the groove. Then place the cover over the rocker in Fit a plate washer and packing washer on each the up the casing with the nuts.
the oil pressure pipe for the rocker mechanism. The pipe is clamped tight with one of the bolts on
Inspection covers for the valve lifters. The inspecers are different on the 32 and can only be fitted in
21 the covers are symmetrical. Apply Permatex to nact surface of the covers and grease the engine's surface. Fit new gaskets on the covers and tighten ets to the engine.. NOTE. Tighten the bolts carefully he exhaust pipe will later prevent any final-tightening cent of leakage.
,
a-water pump
Remove and recondition the sea-water pump. Take off cover and press the impeller out of the pump housing th the help of a screwdriver. Observe due care not to mage the edges of the housing with the screwdriver. The aller is fitted on splines and should be pulled straight
82. Open the circlip (the small one) with circlip pliers and pull out the shaft from one of the housing halves. Remove the brass wear washer. The rubber and carbon gaskets are then accessible for removal. Fit a new, complete set of gaskets.
83. Remove the flange and bearing with the claw puller. The flange has a key. A spacer sleeve is situated on each side of the gear wheel which is fixed on the shaft. Clean and increasary replace parts.
4. Replace the shaft – gear wheel complete. Assemble the pump as follows:
it spacer sleeves on both sides of the gear wheel. Press on e ball bearings. Insert the key and fit the flange. Use a press.
Replace the sealing ring in the "large" housing. Press the aft with bearing onto the housing. Fit the large circlip.
Circulation pump
Release the nut and null off the nulley Pull off the Her with a puller (see Fig.) and take out the water mo seal. Remove the front bearing circlin and drive out rise the shaft with bearing. Take out the other hearing the numn bousing
n defective parts.
88. Grease the ball bearings and fit them onto the shaft with the open sides facing each other.
Press the shaft with bearing into the pump housing and fit the circlip. Tap on the shaft so that the space between shaft, bearing and circlip on the shaft disappears.
Place the water pump packing on the shaft and press on the impeller.
89. The impeller should rotate without sticking. The distance between the numn housing and impeller should be uistance between the pump housing the import should be 0.45— 1mm (0.018–0.040"). Fit the pullev and tighten the nut to a torque of 35 Nm (3.5 kpm = 25 lb.ft.).
90. Apply Permatex to the surface of the fresh-water nump. Fit on a new gasket. Grease the block's contact surface. Fit the pump. Tighten up the bolts diagonally.
Feed pump
91. Remove the cover on the pump and clean the strainer. Check to make sure that the pump is sucking. (A chattering sound is heard when the hand orimer is pressed in.) Fit the strainer and cover and grease the mechanism. Fit the feed nin wich a new O-ring and a fiber packing on each side of the large plate washer.
Fit the fuel pipes onto the feed pump before screwing the pump tight to the engine. Use new seals on the fuel pipes.
Reconditioning the feed pump
92 If the pump does not suck, remove the rubber diaphragm as follows: Turn the diaphragm a bit to the one side is that the manual pump arm releases from the diaphragm recess, see Fig.
93. Press the diaphragm shaft obliquely towards the manual pump arm and turn up the whole diaphragm assembly with the finger tips, see Fig. The finger of the other hand can be used to press in the mechanical pump arm in order to facilitate removal. The new diaphragm is fitted exactly in reverse order, that is, obliquely downwards and turned into mesh with the pump arm. Fit the cover and therk that the pump is functioning ("chatters").
94. The two saml covers on each side of the engine have gaskets which must be replaced if the engine has been washed, since the washing fluid may have ruined the old paskets.
95. Fit the heat exchanger loosely onto the engine. NOTE. First fit on the small rubber hose with hose clamps. (Applies to MD32.) Replace the expansion cover (the old type) for the new one with hose and expansion container, if this has not been fitted previously.
96. Fit the gaskets for the exhaust manifold on the studs. Mount the exhaust manifold and fit washers on all the studs. Tighten up the manifold well with the nuts. NOTE. Nylock nuts should be used on the inside.
Fit the plate with the lift eyelet and gaskets between the exhaust manifold and heat exchanger. NOTE. On the MD21 the lift eyelet faces forwards as shown in the Fig., while on the MD32 it faces rearwards.
Fit the bracket for the fuel pipe on the lift plate. Grease the bolt with the lock wire and tighten it to the heat exchanger. Observe due care that the bolt is not at an angle. On late prod. units, the lift eyelet is screwed into the heat exchanger and the lift plate shortened at the "arrow" (Fig. below)
97. Lower the thermostat into warm water and test with a thermometer to see if the thermostat opens and closes at the right temperature, which is 68–72°C (154–162° F). The thermostat should be fully open at 83°C (181° F). If the thermostat is faulty, replace it. Fit a new packing on the thermostat housing. Tighten up the housing with the two stainless steel bolts (MD32). Stainless steel nuts and washers for the MD21. Fit the rubber hose between the sea-water pump and the heat exchanger. Tighten up the house stainless.
25
5. Check the bearing for the primary shaft. Replace it if imaged, also grease it before fitting. Fit O-rings and guide the for the inner flywheel casing. Fit on the casing and grien it up. Apply Tecyl or similar rustproofing to the add of the flywheel and screw it tight to a torque of 65 m (65 kpm = 47 lb.ft.). Tighten the bolts diagonally. OTE. The tabs on the lock washer should be bent over the of heads. Also rustproof the front side before bolting on a with the table.
b) Fit the sealing ring on the flywheel casing. Check the timary shaft and bearing (applies to AQ version). Press the flywheel casing. Fit the circlips. This applies the shaft and bearing were removed. Before fitting the can with gasket, rustproof the primary shaft well. Fit believelet on the casing as shown in the Fig.
100. On the AQ versions, the drain cocks on the exhaust pipe should be at the front edge and should have an angle union in order to make it easier to get at them. The rear hole is plugged. On inboard engines, the draim cock is placed at the rear edge of the exhaust pipe and does not have an angle union. The front hole is plugged.
The Fig. shows the old type, which should be replaced by the new one during reconditioning.
Adjustment of injection pump
101. Remove the valve cover. Turn the crankshaft until the exhaust valve on cylinder no 1 (nearest the flywheel) closes and the inlet valve opens. The rocker arm for cylinder no. 4 on the MD21 engine is pushed to one side and tool 884473 is placed on the valve. See figure. NOTE! Remove the outer rocker arm on the MD32. Place the tool on the valve afterwards. Remove the collets and the springs. The valve drops down on the cylinder approximately 2 mm.
102. Fit the dial indicator on the valve and rotate the crankshaft until the valve reaches T.D.C. The marking No. 2 on the pulley should now coincide with the marking on the timing gear casing. Rotate the crankshaft anti-clockwise so that the piston goes down 3 mm (0.12"). Observe the dial indicator. Again rotate the crankshaft clockwise 0.96 mm (0.038") for correct adjustment on the MD32, see table under point 108. NOTE. The engine must be turned over clockwise to the indicated value in order to avoid having gear clearance in the measuring. The marking No. 1 on the pulley should now coincide with the marking on the timing gear casing. If the marking does not coincide, then the outer ring on the vibration damper has moved, but this does not require any action.
103. Adjusting the firing position for the MD22 is in the ame way, apart from the fact that the crankshaft should be rotated anti-clockwise 4 mm (0.16") and then again clockwise 1.13 mm (0.04"). NOTE. The engine must be unred over clockwise to the indicated value in order to swiid including gear clearance in the measuring.
The Fig. shows the pulley marking with advanced injection.
105. Remove the pump inspection cover (1) after having taken off the lead seal. Place a new gasket on the pump. Turn the pump pinion until the mark (2) on the rotor is seen in the round indicator hole (3). Fit the dial indicator on the pump and rotate the pump shaft so that the pointer on the gauge goes down into the groove on the rotor. This postition is reached when the maximum reading is shown on the gauge or the pointer can swing no further. Fit the
pump on the engine with the rotor turned so that the mark is seen immediately above the "indicator hole".
104. On the MD21, the No. 4 exhaust valve is removed as follows: Release the adjuster nut and screw up the screw. Then press the rocker arm against the spring and place tool 884473 on the valve.
NOTE. Do not pull up the push rod since the valve lifter can accompany it and come at an angle.
106. When the pump gear meshes, the mark will return to the adjustment in the center of the "indicator hole". Finally, fit the sea-water pump. NOTE. Make sure that the claws go into the fuel injection pump recess.
17. Remove the clearance in the timing gears and the imp parts with the lever (1, Fig. 107). Insert the point tween the shaft (2) and the bolt head (3), then lift the relet upwards and hook the lever round the bolt (4) under e measuring gauge (5). If necessary, turn over the pump for slackening the attacking bolts), to the proper sition, that is, when the gauge pointer goes down into the
V-slot and the gauge gives maximum reading. Tighten up
108. Remove the lever and turn over the engine 1/4 turn anti-clockwise and then slowly clockwise until injection begins. Re-fit the lever. The adjustment is correct when the measuring gauge gives maximum reading, top dead center, when the crankshaft is at the correct advanced injection value according to the table below. Re-adjust if necessary.
Injectors
109. When pressure testing the injectors, the fuel should emerge as an ejected "mist screen". (See "Technical Data".)
The pressure can be adjusted by slackening the upper "nut" and inserting a screwdriver down into the hole and turning clockwise to increase the pressure and anticlockwise to decrease it. Then re-tighten the nut to a torque of 25 Nm (2.5 kpm = 18 lb.ft.). If many directed jets emerge or oil drips from the injector, the injector must be scrapped. Fit a new one and adjust it. When replacing the injector nozzle.
re-tighten the injector nut to a torque of 65 Nm (6.5 kpm = 47 lb.ft.).
110. Place new copper washers (1) in the holes for the injectors and fit the injectors. Fit the yoke and screw on the nuts with their washers. Fit the injector pipes before finally tightening up the yokes.
When the pipes are tightened, tighten up the yokes to a torque of 20 Nm (2.0 kpm = 14 lb.ft.). NOTE. Tighten the nuts evenly so that the yokes do not fit at an angle.
| MD21 | MD32 | |
|---|---|---|
|
Advanced in-
jection angle |
19 0 | 16 0 |
|
Piston B.T.D.C.
(valve stroke) |
2.87 mm (0.113'') | 2.04 mm (0.080'') |
After completing the adjustment, remove the dial indicator and re-fit the inspection cover. Lead-seal the pump. Re-fit the rocker arm and rocker casing.
28
Glow plugs
111. Remove and check the plugs.
he glow plugs are single-pole and connected in parallel.
Troubleshooting table
| Engine | Control resistor | Glow plugs |
|---|---|---|
|
Runs normally
Easy to start |
Dark red or amber | Good condition |
|
f
Difficult to start (See A below) ° |
Glows slightly
or not at all |
Glow coil on one
or several plugs damaged |
|
Does not start
(See B below) |
Glows while and starts melting | Short circuit in elec system or plugs |
On late prod. type engines, the control resistor is located on the engine. The resistor for the MD21 is placed above the alternator on the starboard side. On the MD32, the resistor is placed on the port side above the starter motor. In order to check the resistor, remove it from the engine, but do not disconnect it from the circuit. The troubleshooting procedure is the same as for the early prod. type. See Table.
A Plug's glow coil does not function
If it is suspected that the glow coil on one or several plugs is damaged, disconnect the connection cable, and then wire a control lamp in series with the plug. If the lamp lights, then the plug is in good condition. If the lamp does not light, then the plug is damaged.
B Short circuit in plug
Remove the plugs, one at a time. Connect a 12 V battery to a plug, a clamp on the plug mantle and one on the pole, see Fig. If the holder becomes warm, the plug is in good condition.
Then check the other plugs.
Before alow plugs are re-fitted, their threads should first be greased wiht graphite grease, as this will make subsequent removal of the plugs easier.
Tightening torque = 45 Nm (4.5 kpm = 32 lb.ft.).
Fit the electric bar and tighten up the nuts with a screwdriver. Fit on the protective caps.
112. Fit the leak-off oil pipe (1). Use new packings both sides of the pipe connections. The banjo screws (2) should be tightened carefully. Fit the hose from the leak-off oil pipe to the fuel pump.
113. Fit the bracket for the control cable on the MD32. Use spring washers.
Oil cooler
114. Remove the oil cooler and clean off seaweed, shells and other impurites that can cause poor water circulation, which would result in overheating. Assemble the oil cooler and new O-rings.
116. Screw the drain cock onto the block. Fit the starter motor. The lower bracket has a nylock nut.
117. Fit the pipe for the oil dipstick with new washer.
118. Fit the engine speed sender. Check that the teeth and nylon pin are in good condition. Lubricate the gear wheel well
119. Fit the pipe between the oil cooler and the sea-water pump. Tighten up the hose clamps well.
120. Connect up the oil pipes (from the feed pump) to the fuel filter and from the filter to the fuel injection pump. Remove the check valve from the fuel filter in hole No. 3
'115. Fit the oil cooler on the engine with a new gasket and and clean the valve. Screw back the check valve into position. Tighten up the fuel filter.
121. Fit the alternator and charging regulator. Bind up the cable harness to prevent the cables from getting frayed or damaged in any other way. Fit on the drive belt and tension it by means of the alternator so that it is just possible to depress the belt midway a couple of mm. NOTE. With regard to a dynamo, it should be possible to depress the belt midway about 10 mm (3/8"). Tighten securely the alternator (dynamo). Connect up the cables.
122. Check to make sure that all oil pipes and cables are properly fitted on their brackets.
123. Fit the pipe for the oil scavenging pump.
124. Fit the exhaust elbow with a new packing. Tighten up the bolt inside the exhaust pipe and lock it with lock wire, before tightening up the four outside bolts. The oil scavenging pump is fixed in position by two of the bolts.
125. Fit the intake silencer after cleaning and blowing dry the gauzes in the snorkles. Press on the rubber hose between the intake silencer and the oil filler cap.
126. Close all drain cocks. Replace the fuel filter insert and fit the filter on the bracket. Bleed the fuel system. Fill the engine with oil and water. Concerning oil quality, viscosity and bleeding of the fuel system, see the Instruction Book.
127. Test-run the engine and carry out all check points indicated in the Warranty Certificate under "Delivery Service".
ring diagram: Engine
$
(
4-cyl. engine with dynamo
| LIST | OF COMPONENTS, ENGINE |
| 10. | Battery |
| 11. | Master switch |
| 12. | Starter motor |
| 13. | Charging regulator |
| 14. | Alternator or dynamo |
| Oil pressure sensor | |
| 16. | Engine speed sender |
| 17. | Temperature sender |
| 18. | Glow plugs |
| 19. | Connecter |
| 20. | Relay for glow plugs |
| 21. | Fuses |
| 22. | Control resistor |
CABLE MARKINGS
ΝΛ.
| πk | Colour | sq.mm | AWG |
| White | 6 | 9 | |
| Black | 0.5 | 19 | |
| Black | 1.5 | 15 | |
| , | Black | 4 | 11 |
| •• | Black | 6 | 9 |
| Red | 0.6 | 19 | |
| Red | 2.5 | 13 | |
| Red | 6 | 9 | |
| Red | 10 | 7 | |
| Red | 50 | 0 | |
| Green | 0.6 | 19 | |
| • | Green | 1.5 | 15 |
| •• | Green | 2.5 | 13 |
| Green | 6 | 9 | |
| Gray | 1.5 | 15 | |
| Yeilow | 1.5 | 15 | |
| ; | Brown | 1.5 | 15 |
| 1 | Blue | 1.5 | 15 |
| ł' | Blue | 4 | 11 |
| 4'' | Blue | 50 | 0 |
| • |
Warning
Never break the circuit between the alternator and battery while the engine is running. To do this would be to ruin the charging regulator diodes immediately. The master switch must never be switched off until the engine has stopped completely.
; 32
Instrument panel, 4-cyl. and 6-cyl. engines Early prod.
COMPONENTS, INSTRUMENT PANEL
- 1. Key switch
- 2. Switch for instrument panel lighting
- 3. Temperature gauge
- 4. Warning for low oil pressure
- 5. Speedometer
- 6. Battery charging warning lamp
- 7. Control resistor
- 9. Connector
Instrument panel, 4-cyl. and 6-cyl. engines Late prod.
COMPONENTS, INSTRUMENT PANEL
- 1. Key switch
-
2. Switch for instrument panel lighting
- Temperature gauge
- 4. Warning for low oil pressure
- 5. Speedometer
- 6. Battery charging warning lamp
- . Warning lamp for switching on
- glow plugs
- B. Switch (optional)
- . Connector
- 10. For 24 V
CABLE MARKINGS
| Mark | Colour | sq.നന | AWG |
|---|---|---|---|
| А | White | 6 | 9 |
| в | Black | 0.6 | 19 |
| B' | Black | 1.5 | 15 |
| С | Red | 0.6 | 19 |
| C' | Red | 2.5 | 13 |
| С'' | Red | 6 | 9 |
| D | Green | 0.6 | 19 |
| D' | Green | 2.5 | 15 |
| D'' | Green | 2.5 | 13 |
| ε | Gray | 1.5 | 15 |
| F | Yellow | 1.5 | 15 |
| G | Brown | 1.5 | 15 |
| н | Blue | 1.5 | 15 |
becial tools for AQD21, MD21 – AQD32, MD32
34
Ĉ
¢.
35
-
Technical Data
General
| Type designation | AQD21A, MD21A | AQD32A,MD32A |
|---|---|---|
| Engine type | Indenor XDP 4/90 | Indenor XDP 6/90 |
| Max. output, pleasure boats, SAE at 75 r/s | ||
| (4500 r/m) | 55.2 kW (75 h.p.) | 78 kW (106 h.p.) |
| Bore, mm (in.) | 90 (3.54) | 90 (3.54) |
| Stroke, mm (in.) | 83 (3.27) | 83 (3.27) |
| Capacity, total, dm 3 /liter (cu.in.) | 2.11 (129) | 3.17 (193) |
| Compression ratio | 22.1:1 | 22.1:1 |
| Compression pressure at starter motor r/m, kp/cm 2 (psi) | 24–27 (341–384) | 24–27 (341–384) |
| Firing order, No. 1 cylinder nearest flywheel | 1-3-4-2 | 1-5-3-6-2-4 |
| Max. speed, unloaded engine, pleasure boats, r/s (r/m) | 81 (4850) | 73 (4350) |
| Max. idling speed, r/s (r/m) | 11 (650) | 11 (650) |
. Light-allov
0
3
U-Flex
0.09-0.12 (0.0035-0.0047)
0.30-0.55 (0.0118-0.0216)
1.990-2.022 (0.0783-0.0796)
4.47-4.495 (0.1759-0.1769)
0.06-0.092 (0.0024-0.0036) 0.04-0.072 (0.0016-0.0028) 0.04-0.072 (0.0016-0.0028)
0.015-0.06 (0.0006-0.0024)
Í
£.
Cylinder liners
| Cylinder liners | Wet, replaceable |
|---|---|
Piston
| Material | • • |
|---|---|
| Piston clearance, mm (in.) | • • |
Piston rings
| Piston ring gap measured inring opening, mm (in.) |
|---|
| Piston ring gap measured in ring opening (U-Flex ring), mm (in.) |
Compression rings
| Upper ring chromium-plated | |||||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| Number on each piston | • | • | • |
٠ |
• | • | • |
• |
|||||||
| Height of compression rings, mm (in.) | ·' | • |
|
Oil scraper rings
| Туре |
|---|
| Ring height, mm (in.) |
| Number on each pisto:: |
| Piston ring clearance in groove |
| No. 1 compression ring, mm (in.) |
| No. 2 compression ring, mm (in.) |
| No. 3 compression ring. mm (in.) |
| Il-Elex ring, mm (in ) |
Gudgeon pins
| Float journalling, circlips at both ends | |
|---|---|
| Fit in connecting rod bushing, mm (in.) | 0.013-0.026 (0.0005-0.0010) |
| Fit in poston, mm (in.) | 0.003-0.009 (0.0001-0.0004) |
| Gudgeon pin diameter, standard, mm (in.) | 27.994-28.000 (1.1021-1.1024) |
| Connecting rod bushing, inner diameter, mm (in.) | 28.020-28.007 (1.1031-1.1027) |
Crankshaft
| Replaceable bearing shells for main bearings and connecting | |
|---|---|
| rod bearings | |
| Crankshaft axial clearance, mm (in.) | 0.08-0.29 (0.0031-0.0114) |
| Crankshaft bearing, radial clearance, mm (in.) | 0.046-0.092 (0.0018-01) |
1) Moto-Meter gauge with nipple No. 67
Main bearings
AQD21A,MD21A
Main bearing journals
| Standard, mm (in.) |
|---|
| Undersize, 0,30 mm (0.012 in.), mm (in.) : |
| 0.50 mm (0.020 in.), mm (in.) |
| 0.80 mm (0.031 i.a.), mm (in.) |
| Standard bearing width, mm (in.) |
| Thrust washer, standard, mm (in.) |
| Thrust washer, oversize, mm (in.) |
Big-end bearings
| Radial clearance, mm (in.) |
|---|
| Big-end bearing journals, width, mm (in.) : |
| Big-end bearing journals, standard diameter, mm (in.) |
| Big-end dbearing journals, undersize 0.30 mm |
| (0.012 in.) mm (in.) |
| undersize, 0.50 mm (0.020 in.), mm (in.) |
| 0.80 mm (0.031 in.), mm (in.) |
Connecting rods
| Marking to face towards injection side | |||||||
|---|---|---|---|---|---|---|---|
| Axial clearance at crankshaft, mm (in.) | |||||||
| Only connecting rods of same class are to be fitted in | |||||||
| the same engine | |||||||
| Maximum permissible weight difference, grammes (ozs) | |||||||
| Weight class 2 marked | |||||||
| Weigh class K marked | |||||||
| Weight class F marked | |||||||
Camshaft
| Drive |
|
· |
• |
• • | ٠ |
• |
• | · | · | • | ٠ | • | • | • • | • . • | · | ٠ |
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| Number of bearings |
|
• |
٠ |
• |
• | • | · | • | • | • | • | • | • | • | |||
| Bearing journal diameter, mm (in.) . |
|
• |
• |
• |
• |
٠ | • | • | • | • | ٠ | · | |||||
| End float, mm (in.) |
• • |
• |
• |
• | • | · | • | · | • | • • | ٠ | ٠ | |||||
| Radial clearance mm (in ) |
|
• |
Camshaft bearings
| Rearings | diameter | (in ) | |
|---|---|---|---|
| Dearnings. | ulameter, |
Timing gears
| Crankshaft drive, number of teeth |
|---|
| Idler gear, number of teeth |
| Camshaft drive, number of teeth |
| Drive gear for injection pump, number of teeth |
| Diameter of idler gear shaft, mm (in.) |
| Bushing for idler gear inner diameter, mm (in.) |
| Radial clearance for idler gear, mm (in.) |
| End float for idler gear, mm (in.) |
Valve system
| valves | |
|---|---|
| Inlet: | |
| Valve head diameter, mm (in.) | |
| Stem diameter, mm (in.) | |
| Valve seat angle in O | |
| Seat width, mm (in.) | |
| Valve clearance, cold engine, mm (in.) |
| 55-55.015 (2.1653-2.1659) |
| 54.700-54.715 (2.1535-2.1541) |
| 54,500-54,515 (2,1456-2,1462) |
| 54.200-54.215 (2.1338-2.1344) |
| 37.76-37.81 ′ ≏4866-1.4885) |
| 2.30-2.33 (0.0905-0.0917) |
| 2.50-2.53 (0.0984-0.0966) |
0.045-0.086 (0.0018-0.0034) 36-36.1 (1.417-1.421) 49 99-50 006 (1.9681-1.9687)
49.690–49.706 (1.9563–1.9569) 49.490–49506 (1.9484–1.9490) 49.190–49.206 (1.9366–1.0372)
0.1-0.25 (0.0393-0.0098)
40 (1.4) 5-4-3-2-1-A-B I-J-K-L-M-N-O C-D-E-F-G-H-I-J
Gear
3
4 41.925-41.950 (1.6505-1.6515) 0.05-0.15 (0.0020-0.0060) 0.05-0.11 (0.0020-0.0043)
42-42.039 (1.6535-1.6550)
20 44 40 40 28.98–27.993 (1.1015–1.1020) 28.007–28.020 (1.1026–1.1031) 0.04–0.014 (0.0016–0.0006) 0.05–0.35 (0.0020–0.138)
40.3-40.5 (1.587-1.594) 8.480-8.495 (0.33-0.334) 45 2.82-3.32 (0.011-0.013) 0.15 (0.006)
| ł | |||
|---|---|---|---|
| alve head diameter, mm (in.) | • | ••• | |
| tem diameter, mm (in.) | • | ••• | |
| {alve seat angle in O | • | ••• | |
| eat width, mm (in.) | ٠ | ••• | |
| laive clearance, cold engine, mm (in.) | ٠ |
/alve seats
Valve seats for inlet valves:
| ameter standard (A), mm (in.) | |
|---|---|
| versize 1 (A), mm (in.) | |
| versize 2 (A), mm (in.) | |
| eight (B), standard, mm (in.) | |
| eight (B), oversize, mm (in.) |
Valve seat location, inlet valves:
| Diameter, standard (C), mm (in.) | |
| Oversize 1 (C), mm (in.) | |
| Oversize 2 (C), mm (in.) | |
| Depth, standard (D), mm (in.) | |
| Depth, oversize (D), mm (in.) | |
| Leastion botton radius |
Valve seats, exhaust valves:
| Diameter, standard (A), mm (in.) | •• |
|---|---|
| Oversize 1 (A), mm (in.) | •• |
| Oversize (A), mm (in.) | ••• |
| Height (B), standard, mm (in.) | ••• |
| Height (B), oversize, mm (in.) | • • |
Valve seat locating, exhaust valves:
| Diameter, standard (C), mm (in.) | |
|---|---|
| Oversize 1 (C), mm (in.) | |
| Oversize 2 (C), mm (in.) | |
| Depth, standard (D), mm (in.) | |
| Depth, oversize (D), mm (in.) | |
| Location, bottom radius | |
| NOTE. Measurement between the valve head and cylinder | |
| head face mm (in.) |
Valve guidses
| Length, guide for inlet valve, mm (in.) | |
|---|---|
| Length, guide for exhaust valve, mm (in.) | |
| Inner diameter, inlet/exhaust valves, mm (in.) | |
| Ē | Measured from cylinder head face to valve guide, mm (in.) |
Valve springs
Inner springs
| Length, off load, approx. mm (in.) |
|---|
| Lenght (valve closed) with 7.6 kg (17 lb.) load, mm (in.) |
| Lenght (valve open) with 15.8 kg (35 lb.) load, mm (in.) |
| Length, compressed spring, mm (in.) |
| 33.3-33.5 (1.3110-1.3188) |
|---|
|
8.460-8.475 (0.3330-0.336)
45 0 |
| 2.82-3.32 (0.111-0.131) |
| 0.25 (0.0098) |
42.146-42.171 (1.6592-1.6603) 42.346-42.371 (1.6671-1.6681) 42.646-42.671 (1.6789-1.6799) 5.90-6.10 (0.2322-0.2401) 6.25-6.35 (0.2460-0.2500) inlet val
41.975-42.025 (1.6525-1.6545) 42.175-42.225 (1.6604-1.6624) 42.475-42.525 (1.6722-1.6742) 8.4-8.6 (0.3307-0.3386) 8.7-8.9 (0.3425-0.3504)° Acute angle
36.122-36.147 (1.4221-1.4231) 36.322-36.347 (1.4299-1.4309) 36.622-36.647 (1.4418-1.4428) 5.90-6.10 (0.2322-0.2401) 6.25-6.35 (0.2460-0.2500)
35.975-36.025 (1.4163-1.4183) 36.175-36.225 (1.4242-1.4262) 36.475-36.525 (1.4360-1.4380) 8.4-8.6 (0.3307-0.3386) 8.7-8.9 (0.3425-0.3504) Acute angle
0.75-1.15 (0.0295-0.0453)
55 (2.1654) 55 (2.1654) 8.520-8.542 (0 3354-0.3363) 27.5-28.5 (1.0827-1.1220)
41 (1.6141) 31 (1.2204) 21.5–22.5 (0.8464–0.8858) 20.0 (0.7874)
AOD32A MD32A Outer springs 44.6 (1.7559) Length, on road, approx. min (m, respectively) load, mm (in.) 34 5-35 5 (1 3582-1 3976) 25 5-26 5 (1 0039-1 0433) Length (value open) with 46 kg (101 lb) load mm (in) Length compressed spring mm (in.) 24 (0.0440) Fuel eveter Injection pump, direction of rotation viewed Anticlockwise from flywheel side 1_3_4_2 1 5 2 6 2 4 Injection sequence Fuel injection pump Flance mounted to timing gear casing Evel injection nump make and type CAV Roto-Diesel/DPA 4 00/4850 6 90/4350 Adjusting cylinder . 10, 2 10 Adjusting angle OBTDC 2 04 (0 080) Adjusting angle, mm (in.) 2.87 (0.113) Feed nump GUIOT Make UY-521 A Туре .... Injectors BOTO-DIESEL Make BDN-12SD-6517 PDN 050 .21 Type .................................... 129 5-130 5 119 5-120 5 (1699-1714) (18/1-1855) Make Bosch Туре ..... KE/GSA 9/1 Lubricating system Oil quantity, incl. filter, dm3/liters (imp. ats. 5 5 (4.8=5.8) 8 (7 = 8.4) = US ats.) Oil pressure warm engine (max r/m). 28-3 (40-43) kp/cm2 = psi) ..... Oil pump ..... Gear type Number of teeth 0 16-0 26 0 17 0 27 Tooth backlash, mm (in.) (0.0062-0.0102) (0 0067-0 0106) Clearance between teeth and housing, mm (in.) 0.02-0.06 (0.0008-0.0024) Teahtening torques 20128=501 75 Nm. Cylinder heads, Nm (kpm = Lbft.)
100 (10.0 = 72 Main bearings, Nm (kpm = Lbft.) 60 (6 0 = 43) Big-end bearings, Nm (kpm = lb.ft.) Flywheel, Nm (kpm = Lbft.) ..... 65 (6 5 = 47) 45 (4 5 = 32) Glow plugs, Nm (kpm = lb.ft.) . Crankshaft pulley, Nm (pkm lb.ft.) .................................. 210 (21 = 152) 65 (6.5 = 47) Injector holders, Nm (kp = lb.ft.) Nuts for injector pipes, Nm (kpm = Lbft.) 25 (2 5 = 18) Nut for pulley, Nm (kpm = lb.ft.) 35 (3.5 = 25) Injectors, attaching nuts..... 20 (2.0 = 15)
39
Troubleshooting Scheme
| 1 | |||||||
|---|---|---|---|---|---|---|---|
| Engine does not start | Engine stops |
Engine does not reach
right rpm at full gas (hunts) |
Engine uneven or vibra-
tes abnormally |
Engine becomes abnor-
mally warm |
FAULT | REMEDY | |
|
}
| |
x |
Master switch not switched
on; flat battery, breakage in electric cables. |
Check specific gravity of battery acid with hydrometer. Check cable connections. | ||||
| x | х | Empty fuel tank, shut fuel cock, clogged fuel filter. Air leakage in fuel system. | See Instruction Book for cleaning of fuel filter and bleeding fuel system. Check joint nipples and connections in fuel system. | ||||
| X | х | × |
Water or impurities in fuel.
Defective injectors. |
See pages 24 and 31.
See page 28. |
|||
| } | x | Defective spark plug. | See page 29. | ||||
| X | Defective rev counter. | Check the rev counter. | |||||
| ŀ | X | X | Damaged propeller. | See instruction Book. | |||
| ╞ | × | Boat abnormally loaded. | If possible spread out load to obtain a better and easier running. | ||||
| x |
Marine growth on boat bot-
tom and outboard drive. |
Note! When the boat has been in the water for some
time, the max. engine speed can drop due to marine growth on the boat bottom and outboard drive. Use anti-fouling paint (must not contain copper or mer- cury). Check and clean boat bottom and outboard drive regularly. |
|||||
| x |
Blockage in cooling water in-
take, oil cooler, cooling jackets defective impeller or thermo- stat. |
See page 8, points 16, 17.
See page 20, points 80. See page 30, point 114. |
|||||
| × | Clogged gauze in intake silencer. |
Remove the intake silencer and wash it in white spirit
or similar. Blow clean the gauze in the snorkles, and check to make sure the gauze is absolutely clean. |
|||||
| · } | X | Poor flow through fuel lines. | 1 Check to make sure fuel lines are free from impurities | ||||
| × | Wrong feed pressure. |
2 Connect a low-scale pressure gauge to the inlet pipe on
the fuel injection pump. Feed pressure should be 0.1 kp/cm 2 (14 psi) at full speed and load. If the pressure drops to 0 or below 0, then carry out points 1-6. |
|||||
| ŀ | 1 | X | - | Clogged strainer in feed pump. | 3 Check and clean the strainer in the feed pump | ||
| x | Fine filter clogged. | 4 Check and clean the fine filter. Change filter insert | |||||
| ł | x | Relief valve not functioning. | 5 Check and if necessary change the relief valve. | ||||
| × | Feed pump not functioning. | 6 Change feed pump rubber diaphragm or the entire pump if it is worn. |
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